Maintenance 2sp

Products and functions for
efficient maintenance in the
process automation
Brochure · April 2009
Maintenance System
Answers for industry.
© Siemens AG 2009

Increase in productivity through intelligent
maintenance
How can the productivity of a plant with a high level of au-tomation
be increased even further?
Surveys have indicated that plant operators in all sectors
consider increased availability and shorter downtimes to
be the most effective lever toward increasing productivi-ty.
Investigations have shown that downtimes are fre-quently
the result of insufficient maintenance – despite
the fact that maintenance is already a significant portion
of the lifecycle costs.
Intelligent maintenance strategies can make a significant con-tribution
toward increasing productivity:
• Failures can be prevented by monitoring the current plant
condition.
• Maintenance can then be planned. It does not wait until a
fault has occurred, but implements appropriate measures
in advance for avoiding faults. The timing of maintenance
can be planned such that the existing resources can be
used optimally.
• Innovative maintenance strategies pay for themselves
twice: planning security and the specific application of
methods reduces the direct maintenance costs.
• Plant availability is increased at the same time. This means
that consequential costs resulting from failures, such as
quality deficiencies or loss of image, are reduced.
Totally Integrated Automation supports intelligent mainte-nance
strategies. The SIMATIC Maintenance Station is of sig-nificant
importance, and presents the information relevant to
maintenance from all automation components in a uniform
and clear manner, thus providing the maintenance engineer
with valuable support for making decisions.
Maintenance strategies
There are two maintenance strategies: response to failures or
taking preventive measures. In the case of failure-oriented
corrective maintenance, measures are only initiated when a
fault has occurred, i.e. failures are acceptable in this case and
may be minimized by a redundant plant design.
The objective of preventive strategies is to carry out mainte-nance
measures before faults even occur, in order to avoid
possible downtimes. This strategy can be satisfied using
time-dependent and load-dependent measures. Regular
maintenance work is an example of time-dependent mea-sures.
The load state is determined from the number of
switching operations, operating hours or load peaks.
2 Increase in productivity through intelligent maintenance
Benefits of intelligent maintenance
Continuous plant monitoring
■ Reduces the risk of failures, and increases the
availability
■ Enables maintenance to be planned
Optimized use of maintenance resources
■ Increases maintenance quality
■ achieves cost savings
The potential for savings arises:
■ during maintenance itself and
■ by avoiding consequential costs
Condition Monitoring, that is to say status monitoring, aims
to detect imminent faults at an early stage. It provides infor-mation
on the remaining duration of use. In the case of con-dition-
based maintenance, the maintenance measures are
only initiated when the period of use has expired.
It has been shown in practice that optimum results can be
achieved through intelligent combination of the different
strategies.
Higher operating expenses for condition-based maintenance
will be worthwhile for devices that play a central role for the
availability of a plant and have high replacement costs. But
mostly there are also devices where failures can be faced
without endangering the availability and productivity of the
plant.
Corrective Preventive
Maintenance strategies
Maintenance
Time-dependent
Load-dependent
Condition-based
© Siemens AG 2009

© Siemens AG 2009
Contents
Text
Introduction
Plant-level asset management as a maintenance task 4
Intelligent maintenance in process engineering . . . . . 6
SIMATIC PCS 7 Maintenance Station
More productivity with Totally Integrated Automation 7
Visualization of information for maintenance . . . . . . . 8
Maintenance Station
User interface for maintenance . . . . . . . . . . . . . . . . . . 9
Add-ons as options . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Monitoring and diagnostics
for industrial PCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
for networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
for process sensors and analytical system . . . . . . . . . 16
for positioners and control valves . . . . . . . . . . . . . . . 22
for protective, switching and drive components . . . . 23
Plant-level asset management with
Totally Integrated Automation components . . . . . . . 27
Increase in productivity through intelligent maintenance 3

© Siemens AG 2009
Introduction
Plant asset management as a maintenance task
General information
Various tasks have to be handled during the operating phase
of a plant, for which different groups of persons are responsi-ble.
The production personnel operate and monitor the plant, and
make sure that the desired products are produced with the ap-propriate
quality, in the defined quantity, at a specified time,
and with minimum resources with respect to personnel, raw
materials, energy, costs, etc.
Maintenance staff must
• ensure a high availability of the plant,
• ensure this availability in the long term by implementing
optimization measures, and
• carry out maintenance measures with minimum use of per-sonnel,
material, energy, costs, etc.
As a result of their different tasks, these two groups of persons
have different information requirements.
Different demand for information at the plant:
Plant operator
Information on the process such as:
• Recipe parameters
• Temperature characteristic
• Pressure values
• Raw material stocks
• Output
Maintenance personnel
Information on the state of the production equipment
such as:
• Components OK
• Maintenance required
• Failure
• Functional check
4 Introduction
Information on the measured process tags is available for the
plant operator. Apart from the measured value itself and its
status, this may, for example, be the information on whether
the measured value is still valid.
The focus of interest for the maintenance engineer is the sta-tus
of the production equipment that is reflected in the states
of the devices and components used (i.e. particularly in the
states of the field devices). Typical states in this respect in-clude
"Component OK", "Maintenance required", "Failure" or
"Function check".
SIMATIC PCS 7 allows a clear classification of the information
for the user groups Plant Operators and Maintenance Engi-neers.

Introduction 5
Asset management in production
The term "asset management" comes from the world of fi-nance
and economics and refers to the manner in which a
company deals with its long-term and current assets. These in-clude
the production equipment with its plant components
such as apparatus, machines, pipelines etc. and the equip-ment
and devices for their automation. All these are referred
to as assets. In association with production, asset manage-ment
covers all activities and measures which serve toward re-taining
or increasing the value of a plant. This is called plant
asset management.
Benefits of plant asset management
Plant asset management allows the maintenance engineer
• to unambiguously identify and evaluate the assets, this
means the production equipment and its components,
• to carry out the appropriate measures in the case of devia-tions
from the desired or expected state.
As a result of monitoring, i.e. the recording and evaluation of
status variables, the condition of a component or device can
be determined.
It can be recognized, for example, that no signal is received
from the sensor, resulting in the diagnosis "Open circuit". This
result triggers a maintenance request, and maintenance must
then be carried out to eliminate the open circuit.
This measure – replacement of a faulty line in this example –
ensures that the component is returned to the desired condi-tion
and closes the maintenance cycle. This means that plant
asset management is the basis for increased productivity.
Maintenance Monitoring
measure
Maintenance
request
Diagnostics
© Siemens AG 2009

© Siemens AG 2009
Intelligent maintenance in process engineering
Despite the different tasks of operators and maintenance
staff, it is meaningful and necessary to map the informa-tion
of both staff groups within one process control sys-tem
and not to use different systems.
There are various reasons for this:
• Uniform visualization for all components and devices.
• No limitation to selection of field devices.
• The same information sources (field devices) are relevant
to both automation and maintenance.
• There is a close link between automation and asset man-agement
functions because, for example, the current con-trol
strategy of the plant plays an important role for the as-sessment
of a component status.
• Engineering data for automation can also be used for main-tenance.
• Simplified handling of the system, since users need only be
acquainted with the engineering, operator control and
monitoring tools of a single system.
The process control special interest group of the pharmaceuti-cals
industry (NAMUR) has formulated essential requirements
(NE 91) from the user's viewpoint. This attaches special signif-icance
to the integration of the Plant Asset Management into
the process control system.
• Plant Asset Management is a part of the process control
system
• Recording and assessing the status of the assets
• Inclusion of all assets (process control devices and plant
components)
• Separation of maintenance-relevant information and pro-cess
data
• Uniform visualization for all assets
• No limitation to selection of field devices
6 Introduction
In addition, there is a requirement (NE 107) that all field devic-es
must provide standardized status messages about their sta-tus
as follows:
• Good
no known restriction of function
• Uncertain
Operation outside the specified range
• Device failure
Need for maintenance
• Maintenance required
Function check (process value manipulated)
• Function check, local operation
Failure (process value invalid)
Processing plants, whose open and closed loop control is per-formed
with SIMATIC PCS 7 and components of Totally Inte-grated
Automation, satisfy the user requirements formulated
by NAMUR.
The resulting information is divided up to prevent the plant
operators and maintenance staff from being flooded with in-formation.
To achieve this, a maintenance station (MS) is in-troduced
in addition to the operator station (OS) . Mainte-nance-
relevant information is kept away from the operator
station. This information is collected and presented on the
maintenance station. The same HMI tools are used for the op-erator
station and the maintenance station and the HMI phi-losophy
is identical.
Plant Asset Management with SIMATIC PCS 7
■ Process engineering plants with SIMATIC PCS 7 and
components of Totally Integrated Automation meet the
requirements of NAMUR.
■ Automation and plant asset management run on the
same system.
■ The information for plant operators maintenance staff is
divided between the operator station and the mainte-nance
station.
■ Shared configuration and uniform user interfaces
minimize the expense of an effective Plant Asset
Management.

© Siemens AG 2009
SIMATIC PCS 7 Maintenance Station
More productivity with Totally Integrated Automation
SIMATIC PCS 7 Maintenance Station 7
Integrated plant and cross-system maintenance
Plant asset management is only truly productive if mainte-nance
staff can view diagnostic information relating to the en-tire
process chain at a glance. In practice, this means that: In-bound
and outbound processes such as logistics, bottling and
packaging plants must be capable of support by the same
maintenance team that is responsible for the actual process,
without a great deal of additional expertise having to be built
up. If the process control system and the controllers of the up-stream
and downstream systems originate from the same
vendors, different alarm systems can cause considerable addi-tional
expense.
If a plant is automated with SIMATIC PCS 7, therefore it is
worthwhile for the plant operators to select machines and sys-tems
that are automated with SIMATIC and visualized with
SIMATIC WinCC for their inbound and outbound processes, as
then they can exploit all the advantages of Totally Integrated
Automation.
If machines or systems for inbound or outbound processes are
operated and monitored by means of SIMATIC WinCC, then
the SIMATIC Maintenance Station presents itself as an option
to the SIMATIC WinCC SCADA system for the display of main-tenance-
relevant information.
The integrated functionality of Totally Integrated Automation
also makes it possible, using the SIMATIC PCS 7 Maintenance
Station, to monitor the packaging or bottling line by means of
a client. In other words: the maintenance information from
the process control system and SCADA system can be merged
on a central Maintenance Station. Display, logic, and message
management are identical. The uniform look and feel saves
on overhead and generates a high degree of acceptance with-in
the maintenance team. The SIMATIC Maintenance Station
for SIMATIC PCS 7 and SIMATIC WinCC makes a significant
contribution to increasing maintenance productivity and thus
to increasing the availability of the overall plant.
Optimizing instead of repairing
The task of maintenance is not only to avoid unscheduled pro-duction
downtimes, but also to optimize the running of the
plant. Optimization must be based on analysis of traceable
processes. The maintenance station offers the basic data set
for integrated analysis of all weak points. This is not unusual
in a process control system. However, in inbound and out-bound
processes diagnostics are often restricted to signaling
a fault and then forgetting about it as soon as it has been re-paired.
With Totally Integrated Automation, the maintenance
station becomes the basis for Total Productive Maintenance.
Central control room with plant-wide maintenance overview
Inbound process Productions process Outbound process
G_ST80_XX_00337
Maintenance Station
Server (WinCC)
Maintenance Station
Server SIMATIC PCS 7
,QWHUQHW
Maintenance Station
Server (WinCC)
Maintenance
Station Client
+ Web Server
Maintenance
Station Client
SIMATIC Maintenance Station: Collecting diagnostic information from the entire process chain centrally – even via the Web

Visualization of information for maintenance
In order to recognize the conditions of individual devices
or components unequivocally, a uniform symbol repre-sentation
has been implemented.
There are symbols for the device status itself and also for the
importance of a maintenance request. In addition, the status
of a maintenance measure is displayed. The conditions of all
devices and equipment of the automation technology and of
the plant components are indicated by these standardized
symbols.
Uniform symbols for the conditions of components and devices
Besides the uniform display of symbols, a significant detail for
the overview is a hierarchical structuring of information in
which the maintenance engineer also has access to all re-quired
details of the components and devices, based on an
overview display (plant view).
Extract from the hierarchical visualization of the maintenance
information.
8 SIMATIC PCS 7 Maintenance Station
The overview display uses the standardized symbols to visual-ize
the condition of a component itself and also provides col-lective
information on the conditions of all devices in the sub-ordinate
hierarchies.
The collective condition message shows the OK condition or
the seriousness of a possible problem in red, yellow, or green,
as per a traffic light. A button can be used to access all subor-dinate
hierarchy levels step-by-step down to the bottom de-vice
level.
Further views of the maintenance information are available in
addition so that the maintenance engineer has a complete
overview of all current information of the asset relevant to
maintenance. This permits assessment of the plant status at a
glance.
Detailed view of a component
The information is consistently structured and hierarchically
organized. The quantity of information displayed on each in-dividual
screen always remains manageable for the mainte-nance
engineer, who nevertheless has easy access at any time
to the complete information.
0DLQWHQDQFH
MREXQNQRZQ
QRWUHTXHVWHG
0DLQWHQDQFH
UHTXLUHPHQW
ORZ

*RRG
6LPXODWLRQ
/RFDORSHUDWRU
FRQWURO
0DLQWHQDQFH
MRE
UHTXHVWHG
0DLQWHQDQFH
MRE
EHLQJSURFHVVHG
2YHUYLHZ
$XWRPDWLRQ
VVWHP$6

'HWDLOHGYLHZ
RPSRQHQW
'HYLFH
3ODQWYLHZ
$6UDFN

$6UDFN 6XEQHW
Q
© Siemens AG 2009

© Siemens AG 2009
Maintenance Station – User interface for maintenance
The SIMATIC PCS 7 Maintenance Station software package
is available as an alternative to SIMATIC PCS 7 for imple-menting
plant asset management. You can use this soft-ware
package to expand an Operator Station to a
Maintenance Station.
The maintenance engineer can process the diagnostics mes-sages
and maintenance requests of the assets on the mainte-nance
station. Via the maintenance station the engineer can
access:
• components of the process control system: intelligent field
devices and I/O modules, field bus, controller, network
components and plant bus as well as servers and clients of
the operator systems.
• assets that do not belong directly to the process control
system, such as pumps, motors, centrifuges, heat exchang-ers
or control loops (passive or indirect assets). These are
represented by proxy objects in which the diagnostics rules
are stored.
Standard diagnostics functions
In order to obtain information on the diagnostics status of in-dividual
plant areas or components, maintenance engineers
can change from the overview display to the respective diag-nostics
display of the subordinate hardware level. If a fault is
signaled in the overview display, the loop in alarm function
permits rapid switching to the diagnostics faceplate of the as-sociated
component. The information is filtered according to
the area of responsibility of the user.
The following information can be offered:
• Display of diagnostics status determined by the system
• Information on the component, such as process tag name,
manufacturer or serial number
• Display of diagnostics messages of a component
• Visualization of type and current state of initiated mainte-nance
measure
Information on passive or indirect assets
For passive or indirect assets without self-diagnostics (pumps,
motors, control loops etc.), inadmissible operating states can
be derived from various measured values and their deviations
from a defined normal status using the programmable logic
block AssetMon.
These are displayed as a maintenance alarm on the mainte-nance
station. With the aid of the AssetMon, individual diag-nostics
structures, project-specific diagnostics rules and con-dition
monitoring functions can be implemented.
Construction of a maintenance station
The SIMATIC PCS 7 Maintenance Station is of modular design.
In small plants it is possible to install the operator station and
the maintenance station on the same PC. Just like the opera-tor
system, the maintenance station can be expanded into a
client/server application with multi-client operation.
The signals and messages from the components and devices
which are relevant to maintenance are collected and saved on
the server of a client/server application. They are displayed on
the client.
The SIMATIC PCS 7 Maintenance Station is based on standard
SIMATIC products:
• SIMATIC PCS 7 ES / OS
for configuration and HMI functions,
• SIMATIC PDM
for connecting the field devices and
• SIMATIC SNMP OPC Server
for interfacing network components

Maintenance Station – User interface for maintenance
Configuring a maintenance station
When setting up a Maintenance Station, the user only has to
assign the corresponding attribute once during the configura-tion.
This automatically generates a technological hierarchy
for diagnostics displays. The diagnostics displays can be sub-sequently
expanded by project-specific contents.
When configuring PCS 7, the technological plant view automatically
becomes its own maintenance area
Visualization in the maintenance station
In the operating state, the maintenance station's client re-quests
cyclic data from the associated server. The client can
additionally access hardware components and field devices di-rectly
by means of an on-line connection, so that the mainte-nance
engineer has the relevant information available at all
times. Various components with highly different diagnostics
capabilities are used for SIMATIC PCS 7. However, from the
viewpoint of maintenance, all components are displayed in
the same manner. Therefore the maintenance and diagnostics
conditions of the components are represented by standard-ized
symbols.
The symbols indicate the maintenance status
• of a component (maintenance state display)
• of subordinate devices (maintenance group display)
• and, if applicable, the status of maintenance
work (operator state display).
Overview of components on a PROFIBUS segment with symbol displays
Symbol displays and component faceplates
The conditions of the compo-nents
or also of subordinate
components are visualized
using standardized symbol
displays in the diagnostics dis-plays.
The symbol displays of
the components contain:
• Bitmap of component
• Tag designation of compo-nent
• Maintenance state display
• Group display for maintenance messages from subordinate
components
Clicking an element in the symbol display either opens the
subordinate hierarchy level or a component faceplate. This
faceplate contains various views of the respective component
in which further device-specific information can be output.
There are three standard views:
Identification:
Depending on the component, the identification view dis-plays
all information available from the hardware configura-tion
or via SIMATIC PDM in the device description, of the Elec-tronic
Device Description (EDD). In addition, the maintenance
status is displayed and, if available, the status of a redundant
component.
Messages:
The Messages view displays diagnostics error messages, oper-ator
inputs and maintenance requests.
7HFKQRORJLFDOSODQWYLHZ
0DLQWHQDQFH
6WDWLRQ
7UDQVIHURIPDLQ
WHQDQFHUHOHYDQW
LQIRUPDWLRQWRWKH
0DLQWHQDQFH6WDWLRQ
2SHUDWRU
6WDWLRQ
Symbol display of a component
© Siemens AG 2009

© Siemens AG 2009
Maintenance:
The maintenance view is used for the response of the operator
to a maintenance request of a component. Maintenance work
can be requested. The status of the work can also be specified.
This is recorded, and signaled in the symbols. A work instruc-tion
number and a comment can still be entered for each work
request. The instruction number has no effect within the
Maintenance Station and is only included in the report. This
can be used for transfer to maintenance planning.
Faceplate for maintenance view
Process Device Management
Depending on the diagnostics capability of a device, there are
additional views. For example, in the component operating
display for intelligent field devices (DP, PA, HART), additional
information is output that the Process Device Management
(PDM) makes available. Changes in the parameterization are
managed in a change logbook and can be called up from the
Maintenance Station. In this case, the time and name of the
responsible operator are output.
Configuration changes can also be output. The diagnostic in-formation
of intelligent field devices is determined with the
PDM on the basis of the EDD of a field device. In the EDD, the
device manufacturer also specifies, for example, the supple-mentary
information to be provided in the event of faults. This
can also display the cause, a trend statement and instructions
for clearing the fault. In addition, PDM can be called directly
from the faceplate. This call makes all vendor-specific infor-mation
and documents incorporated by the vendor available
for intelligent field devices .
Faceplate, detail view of a component

© Siemens AG 2009
Add-ons as options for the SIMATIC PCS 7 Maintenance Station
Alarm Control Center alarm management system
The WinCC Alarm Control Center (ACC) alarm management
system transmits alarms from visualization and control sys-tems
to mobile receivers such as cellphones or pagers.
The messages are automatically sent to the responsible per-son
or group of people. If no response is received within a pro-grammable
period of time from a notified person (such as a
text message), other people are notified. In conjunction with
the escalation system, alarm scenarios can be implemented
for a wide range of requirements.
Even the basic package incorporates a shift management fa-cility,
enabling personnel to be assigned depending on the
time and the day of the week.
Text messages are sent via ISDN, analog modem or GSM mo-dem.
For additional requirements, transmission channels are
available for systems including VOIP, voice and PABX systems.
Configuration and user control is web-based, via LAN or Wire-less
LAN.
Further options allows the Alarm Control Center to be adapted
to individual requirements. The Replication option enables
high-availability, redundant systems to be configured. The Di-alog
module permits active contacting of stations, such as to
log off a station by remote configuration or to query process
values. Advanced call archive analysis enables detailed logs to
be generated, and supports other quality assurance mea-sures.
Further information:
www.siemens.com/alarmcc
PM-MAINT intelligent maintenance management
The PM-MAINT add-on supplements the SIMATIC Mainte-nance
Station with the following functions:
Maintenance planning
PM-MAINT can be used for planning, based on performance
data or calendar intervals, so as to define clearly when which
maintenance tasks are to be carried out. Damage reports and
repair jobs from the SIMATIC Maintenance Station also enable
unforeseen maintenance work to be scheduled.
Management of supplementary information
Data essential to effective maintenance can be entered relat-ing
to the maintained plant and machinery. In addition to
component, manufacturer and sourcing data, electronic doc-uments
can also be linked to the items and related mainte-nance
jobs. This provides maintenance staff with direct access
to aids such as repair instructions, circuit diagrams, photos,
manuals and the like.
PM-MAINT status window
Archiving of maintenance data
All maintenance activities are logged in an archive. Analysis of
the archive enables maintenance operations to be assessed in
detail, providing for continuous improvement.
Further information:
www.siemens.com/pm-maint

ವ 'LDJQRVWLF/('VRQHDFK
XQLW
ವ /RFDORQRZQPRQLWRU
ವ 9LD/$1RQWKHFHQWUDO
VHUYHU
ವ *UDSKLFGLVSODRI
PHDVXUHGGDWD
ವ :HEVHUYHU
ವ 6,0$7,
0DLQWHQDQFH6WDWLRQ
Monitoring and diagnostics 13
Monitoring and diagnostics
for industrial PCs
SIMATIC IPCs are rugged industrial PCs for professional au-tomation
solutions in 24-h operation. Because of their
high system availability, in PCS 7 systems they are often
used, for example, as operator or maintenance station or
also as engineering station or OPC server.
The SIMATIC PC DiagMonitor monitoring and signaling soft-ware
recognizes possible hardware and software faults at an
early point in time, and provides corresponding messages for
the Maintenance Station. In connection with several SIMATIC
IPCs, client/server network architectures can be set up via LAN
and can centrally monitor all SIMATIC IPCs in plant facilities
using DiagMonitor. The integrated webserver lets you view
and manage data via an internet browser. Efficient service
structures can be established by integrating automated com-munication
paths, e.g. by means of Ethernet, e-mail, or text
messages (phone).
DiagMonitor supplements the operating data of the moni-tored
PCs with text messages, transmits them via the SNMP
OPC server and outputs them in the associated asset manage-ment
view.
• The Monitoring 1 view indicates the number of operating
hours of the SIMATIC IPC and the interior unit temperature
at different measurement points in the device, e.g. at the
processor and at the motherboard.
• In two additional views the speeds of the fans are output or
diagnostic data and information on the status of the drives
is displayed. It is then possible, for example, for the user to
replace hard disks as a preventive measure before a loss of
data occurs (preventive maintenance).
Operating hours and device internal temperatures in the Monitoring View 1
In addition, the user is warned in good time of fan or hard disk
failures (preventive maintenance). In the event of an alarm,
the DiagMonitor can also start autonomous programs such as
special PC tools or user-specific applications for individual
response to alarms.
Prevention of potential failures
• Diagnostics and signaling functions for PC temperature,
fan, hard disks (SMART), system status (watchdog)
• Operating hours counter for preventive maintenance
• Recording and evaluation of operating data
• Integral log function, comprehensive text messages
and online help in German and English
Possibilities for minimizing PC downtimes:
• Product Equipment Data: Online service tool for simple and
quick information about the equipment configuration in
the delivery condition. The information also supports the
procurement of spare parts (www.siemens.com/ped).
• The after-sales information system for SIMATIC IPC/PG of-fers
product and contact information on the Internet in one
central location (www.siemens.com/asis).
The SIMATIC PC DiagMonitor supports fast detection and efficient avoidance of potential system failures
2SHUDWLQJDQG
0RQLWRULQJ 6LJQDOLQJ $OHUWLQJ 9LVXDOL]DWLRQ UHFRUGLQJ
ವ3KDUGZDUHIXQFWLRQV
ವ,QWHULRUXQLWWHPSHUDWXUH
ವ'HYLFHIDQ
ವ+DUGGLVNVWDWH
ವ6VWHPVWDWHV
ವ5XQWLPHPHWHU
ವ 2YHUVKRRWXQGHUVKRRW
RISHUPLVVLEOHRSHUDWLQJ
WHPSHUDWXUH
ವ)DQIDLOXUHIDXOW
ವ+DUGGLVNSUREOHPV
ವ3URJUDPLQWHUUXSWLRQ
IROORZLQJDZDWFKGRJ
WLPHRXW
ವ0DLQWHQDQFHLQWHUYDOV
IUHHOVHOHFWDEOH

ವ /$1
ವ 7H[WPHVVDJHWRPRELOH
SKRQH
ವ (PDLOWRDOHUWGHVLJQDWHG
SHUVRQ
ವ 23DQGRU6103WR
XVHUVRIWZDUH
ವ $FWLYDWHVUHVHW
ZDWFKGRJ

ವ 5XQVSURJUDPV
DXWRPDWLFDOO
EDWFKH[HFXWDEOHILOHV

© Siemens AG 2009
Monitoring and diagnosis of networks
SIMATIC PCS 7 communicates with the subordinate com-ponents
of Totally Integrated Automation via Industrial
Ethernet and PROFIBUS and uses the network components
and communications processors (CPs) of SIMATIC NET. In
addition to reliable communications, these also offer the
facility for network diagnostics during runtime.
Monitoring of PROFINET/Industrial Ethernet
Network components
Network components are SCALANCE X (Industrial Ethernet
switches), SCALANCE W (Industrial WLAN), and SCALANCE S
(Industrial Security).
SCALANCE X-200 managed
Universally applicable, from machine-level applications to
networked plant sections. Configuration and remote
diagnostics are integrated in the STEP 7 engineering tool. This
increases plant availability. Devices with a high degree of pro-tection
permit a cabinet-free construction. Appropriate
switches (SCALANCE X-200IRT) are also available for use in
plant section networks with hard real-time demands and max-imum
availability.
SCALANCE X-300 managed
Networking of subsystems/plant sections, as well as for con-necting
to the enterprise network. The SCALANCE X-300 man-aged
product line combines the firmware functionality of
SCALANCE X-400 with the compact design of SCALANCE X-
200. The SCALANCE X-300 switches thus offer expanded
management features and firmware functionality in compari-son
with the SCALANCE X-200 switches. Moreover, electrical
and optical Gigabit Ethernet ports are available, as well the XR-
300 Rack Switches as versions in 19-inch design.
SCALANCE X-400 managed (Layer 3)
For use in high-performance plant networks (e.g. with high-speed
redundancy). Due to the modular design, the switches
can be adapted to the task at hand. Due to the support of IT
standards (e.g. VLAN, IGMP, RSTP), the seamless integration
of automation networks into existing office networks is possi-ble.
Routing functions on Layer 3 support communication
between different IP subnets.
SCALANCE W
Thanks to wireless communication, an even higher level of
plant flexibility can be achieved, maintenance work is simpli-fied,
and service times and downtimes are reduced. The
IWLAN solution from Siemens Industry makes these advan-tages
available through a coordinated portfolio of WLAN
equipment for industrial use, even for fail-safe communica-tion
in the context of operator and machine safety. This
includes IWLAN access points and client modules (SCALANCE W),
14 Monitoring and diagnostics
Selection of network components with diagnostics capability
wireless connections for PROFIBUS and distributed I/Os,
mobile operator panels, planning software, and extensive
accessories.
SCALANCE S
The SCALANCE S security modules enable logging of access
data in one log file (syslog protocol). These data show how,
when, and by whom the network has been accessed. Attack
attempts can be detected early and appropriate preventive
measures taken.
Network management
The integrated network management with the standard
SNMP (Simple Network Management Protocol) in SCALANCE
X and W provides information for the diagnosis of devices.
The network management products SINEMA E (SIMATIC Net-work
Manager Engineering), SINEMA Server (Management),
and the SNMP OPC server provide support in the planning and
simulation or monitoring and diagnosis of wireless and wired
networks in the industrial environment. SINEMA Server is spe-cifically
used in larger networks and for extensive network
management. The SNMP OPC server is used exclusively for the
processing of SNMP message frames and their transfer to be
represented in other systems.
SINEMA Server network management
The SINEMA Server (Simatic Network Manager) network man-agement
software diagnoses and visualizes Ethernet net-works.
It continuously logs network activities using various
protocols such as SNMP, DCP, and LLDP and makes them avail-able
to users and other systems on the network, e.g. HMI soft-ware
such as WinCC, for evaluation and further processing.
Devices, their properties and their topology are recognized,
and network statistics are compiled by means of autodiscov-ery.

© Siemens AG 2009
These can be displayed graphically and if desired also supple-mented
using individual diagnostics screens. In addition, at
runtime cyclical data from Ethernet participants is queried and
network alarms are reported. Websites are used to present
and pass on the information. Furthermore, the software offers
an e-mail client function and OPC server in order to forward
network data and alarms to other systems. SINEMA Server can
be easily integrated in HMI (Human Machine Interface) and
visualization systems such as SIMATIC WinCC. Changes in the
network are also accordingly logged and archived in a
database. For the analysis of past network failures or as
evidence of network availability, the database information can
be prepared and documented as reports for any configurable
period of time. The SINEMA user interface and its available
features are accessible via the browser from any computers on
the network.
The following components can be diagnosed:
• SCALANCE X and W network components
• SIMATIC NET Industrial Ethernet CPs
• SIMATIC S7 with integrated PROFINET interface
• PROFINET IO devices, e.g. ET 200
• Other Ethernet devices
SNMP OPC server
The SNMP OPC Server enables diagnostic and configuration
data to be read from any Ethernet devices and displayed on
the Maintenance Station. Alongside standard maintenance
data, simple plant network problems such as failure of a line
can be quickly and easily detected by means of this software.
Device configuration is integrated into STEP 7. Ethernet
devices can be read from a STEP 7 project or, using the auto-discovery
function, directly from the live network. The user
can easily add all devices detected there to the device list for
monitoring on the OPC Server. Then this configuration data is
exported into the Maintenance Station, where tags, alarms
and faceplates are automatically created for the devices con-cerned.
Monitoring of PROFIBUS
Online diagnostics with diagnostic repeater
Particularly in the case of exceptional stress, e.g. trailing
cables or strong vibrations, frequent inspection of the cables
is recommended to reduce failures to a minimum. The diag-nostic
repeater is available for this purpose. It is integrated as
an RS 485 repeater in the PROFIBUS network and also has
powerful features for the diagnosis of cable faults.
The diagnostic repeater determines the topology of the
bus system. If there is a fault, a standard diagnostic message
is automatically transmitted to the master.
This means that even sporadic cable faults can be detected
and signaled. Even maintenance engineers without PROFIBUS
expertise can also quickly and reliably locate and fix bus cable
faults.
Diagnosis of optical PROFIBUS links with OLM
To set up optical PROFIBUS connections, optical link modules
(OLMs) are used. They offer the following diagnostic options:
• Function monitoring by means of signaling contact
• Signaling of the fiber-optic cable quality with LEDs for
channel monitoring
• Analog value signaling of the fiber optic line quality; evalu-ation
with voltmeter via measurement terminal or reading
to the PLC via analog module
Benefits of network monitoring and diagnosis
• High network availability through targeted and rapid local-ization
of faults
• Documentation of network activities for analysis and verifi-cation
of network availability
• Monitoring and improving network utilization
• Automatic detection of new or faulty participants
• Integration of diagnostics data in automation and visualiza-tion
systems
• Detailed and clear graphical network representation

Monitoring and diagnostics for process sensors and analysis
Standardized and meaningful diagnostics alarms are a
part of the electrical device description (EDD). SIMATIC
PCS 7 utilizes the EDD and forwards the relevant message
automatically to the Maintenance Station. The user
receives information not only about which problem is
involved, but also on how to resolve it.
The PROFIBUS profile specification 3.01 supplies an upgrade
of the status byte, now designated Condensed Status. The
purpose of the Condensed Status is to reduce the number of
alarms and make them more user-friendly. In addition, users
have the opportunity of changing the priority level for each
diagnostic alarm and thus define what is relevant to their own
process.
Numerous EDDs are currently being upgraded to Extended
EDDs (EEDDs). They have the following advantages:
• new standardized look feel for all Siemens devices
• Quick start wizards for faster commissioning
• improved graphics for advanced diagnostic functions
For most Siemens devices, the manual is part of the EDD.
When using PROFIBUS, Asset Management functions can be
used to greatest effect if the devices used conform to the
PROFIBUS Identification and Maintenance specification as
well as profile specification Version 3.01. Siemens devices
conform to these standards. According to the Identification
and Maintenance specification, the information to be made
available should include the following:
• Manufacturer
• Order Nos.
• Description
• Installation date
• Serial number
• Hardware and software changes
As the information is also available in the device, it can be
read from the configuration software and permanently stored
in the software memory.
Temperature measurement
SITRANS T are the temperature measuring instruments for
process engineering plants. By means of intelligent technol-ogy,
these devices provide optimum support for the commis-sioning
and maintenance. Due to various designs such as
complete measuring points, head-mounted transmitters, or
rail-mounted or field devices, the user has a great deal of free-dom.
For preventive maintenance, for example, the following
functions are available in all devices:
• Universal connection of resistance thermometers, thermo-elements,
resistance-type transmitters and DC voltage
signals.
• Monitoring of the measuring point for short circuit and
open circuit.
• Min/max pointer for monitoring the electronics and sensor
temperature.
The following devices are available as head-mounted trans-mitters
or integrated into a complete measuring point:
SITRANS TH300 – the HART device:
The operating hours counter evaluates the temperature val-ues
of the sensor and electronics, edits them and displays
them in eight temperature classes. The measured values can
be archived. It is possible to derive a strategy for prognostic
maintenance from the sensor temperature loading – if aging
processes are known.
The output current is monitored cyclically, simulated as a fixed
value or ramp function.
• Memory function of RAM, ROM, EEPROM according to
checksum method
• Program sequence due to targeted approach to check-points
(watchdog)
SITRANS TH400 for
PROFIBUS PA
With the possibility of con-necting
two sensors in redun-dant
mode. The profile 3.0
device ensures easy inter-changeability.
With FISCO certification, use
in potentially explosive areas
is uncomplicated.
SITRANS TH 400
SITRANS TW for
rail mounting
For installation on mounting
rail with integrated power
supply, SITRANS TW is a uni-versal
4-wire temperature
transmitter for mounting in
control cabinets:
• Monitoring of limit values
and output via HART or
signaling relay
• Runtime meter for elec-tronics
SITRANS TW
© Siemens AG 2009

© Siemens AG 2009
Pressure, absolute pressure, differential pressure, flow
and hydrostatic level measurement
SITRANS P is a family of pressure measuring instruments. The
SITRANS P DS III and P-300 digital transmitters are suitable as
universal transmitters for measuring gauge pressure, abso-lute
pressure, and differential pressure, and also for flow and
hydrostatic level measurement.
They have a series of integrated diagnostic and simulation
functions that allow the user to assess the specific state of the
device or of the whole measurement point during commis-sioning,
servicing and maintenance operations.
The preventive maintenance is supported by functions such
as
• Operating hours counter for measuring cell and electron-ics.
• Event counter for upper and lower limit violation
• Min/max pointer for pressure, sensor temperature and
electronics temperature
• two freely parameterizable timers that can set off a warn-ing
or an alarm on reaching a preset threshold.
As part of the corrective maintenance the device diagnostics
effectively support the clearance of faults. For this, the follow-ing
are cyclically monitored:
• Memory integrity of RAM, ROM and EEPROM by means of
checksum method
• Correct program sequence in microcontroller due to tar-geted
approach to checkpoints (watchdog)
• Sensors for breakage and function of the linearization cal-culation.
In addition, simulation functions are available for checking
the configuration of the transmitter and of the connected
control system input. These also contribute to fast and defini-tive
troubleshooting and thus to greater efficiency in the
maintenance operations.
From the combination of the stated functions, measures can
be derived that contribute to the prognostic maintenance
and thus increase plant availability even further and help to
raise productivity.
SITRANS P DS III
SITRANS P 300, digital display

© Siemens AG 2009
Flow measurement
For flow measurement, Siemens offers various contactless
measurement procedures:
• SITRANS F M MAGFLO magnetic-inductive flow meters
• SITRANS F C MASSFLO Coriolis mass flow meters
The devices are flexible in their application and can be posi-tioned
at any point in the installation.
MAGFLO and MASSFLO flow meters provide excellent, correct
and predictable information about the HART or PROFIBUS Pro-fil
3.0 interfaces. The latest MASSFLO version SIMATIC Siflow
FC070 Coriolis transmitter can be directly integrated into the
SIMATIC system via the backplane of the SIMATIC module.
SIMATIC Siflow FC070 has a SIMATIC S7-300 environment.
The SIMATIC Siflow FC070 permits seamless integration into
the automation system.
MAGFLO flow meters are used for applications with conduc-tive
liquids and MASSFLO flow meters, for example, for non-conductive
liquids, high precision requirements or in pro-cesses
in which the process parameters are subject to severe
fluctuations.
MAGFLO flow meters are not sensitive to fluctuations in tem-perature,
pressure, viscosity or electrical conductivity (min. 5
μS/cm guaranteed).
The device is equipped with a host of diagnostic functions that
are displayed in plain text and stored in a logbook. In this way,
sporadically occurring faults can also be located. These faults
are automatically sent to the system in accordance with the
standards of the diagnosed requirements of Namur NE 107.
The measuring transducer, including outputs, is monitored.
The pickups are continuously checked and empty pipe detec-tion
is performed. In addition, MAGFLO flow meters offer the
option of checking the entire measurement system with an
external verifier.
SITRANS F M MAGFLO
MASSFLO flow meters are not sensitive to fluctuations in pres-sure,
temperature, density, electrical conductivity or viscosity.
An ASIC guarantees improved reaction to discontinuities. The
devices are practically unaffected by external noise – an
essential requirement for raising the dynamic range.
MASS 6000 monitors both application-dependent faults
and those device settings selected by the user:
• too much air in the measuring tube
• Empty tube detection
• Unstable flow signal
• Zero point error
• Density of fluid and temperature limits
• Measuring range limits
The user-specific settings are compared with the actual values
to determine an optimal setting. Faults, caused by mechanical
vibrations, cavitation or pump noises can affect the measure-ments.
Extended diagnostic functions in the MASS 6000 transmitter
by means of intrinsic sensor resonance frequency, pick-up
amplitudes and signal-phase can identify these influences.
As NAMUR NE 107 is supported, extensive diagnostic func-tions
are available in the Maintenance Station. This enables
the maintenance personnel to adopt the necessary measures.
From this standardized information (type and frequency of
the alarms), the user can draw conclusions that indicate immi-nent
failure or predictive maintenance. This enables step to be
performed to improve the measurement quality or prevent a
loss of production.

:HDUDQG
WHDU )LUVWPHVVDJH 6HFRQGPHVVDJH
*RRG 0DLQWHQDQFH )DLOXUH
UHTXHVW
$FXWH 7LPH
0DLQWHQDQFH
UHTXLUHPHQW
/HDGWLPHIRUSODQQLQJ
$GMXVWDEOH
Level measurement
© Siemens AG 2009
Three different measurement procedures are available for
level measurement: Radar technology, capacitive level mea-surement
and ultrasonic technology.
Level measurement with contactless radar technology:
• SITRANS LR400/LR460 with FMCW radar
(Frequency Modulated Continuous Wave)
• SITRANS LR200, Pulse Radar
• SITRANS LR300, Pulse Radar
• SITRANS Probe LR, Pulse Radar
Level measurement with contactless ultrasonic technology:
• SITRANS Probe LU with ultrasonic compact echo sounder
Capacitive level measurement with limit recording
• POINTEK CLS 200/300/500
• SITRANS LC 300/500
Siemens level meters have a series of internal and external
monitoring functions. For example, the Pointek CLS
200/300/500 limit switches offer the opportunity of detecting
external influences such as deposits or pollution and deriving
maintenance requirements from them.
The device diagnosis includes not only the typical electrical
and electronic components, but also the assessment of the
signal for its measurement quality with regard to it trustwor-thiness
and strength. The Maintenance Station reports the
maintenance requirements on reaching a limit value.
SITRANS LR400/LR460 cumulates the operating data and cal-culates
from it the remaining life in terms of the preventive
maintenance.
SITRANS LR400
SITRANS LR, LC and LU for filling level monitoring
POINTEK CLS200/300 recognizes the degree of encrustation.
The current status of the device in each case is the basis for the
predictions of remaining life. This makes prognostic mainte-nance
possible. Maintenance measures can be planned to
maximum effect. The result of maintenance work already
carried out is also fed into the trend calculation.
Due to their design and the patented Active Shield Technol-ogy,
SITRANS LC300/LC500 are suitable for difficult applica-tions,
in which reliable measurement and high accuracy are
important, virtually unaffected by material deposits or pollu-tion.
They have a greater fault-tolerance than comparable
devices. The need for maintenance is reduced to a minimum.

:DUQLQJOHYHO
$GMXVWDEOH
:DUQLQJOHYHO
$GMXVWDEOH
$GMXVWDEOH

Adjustable limit values for the various warning levels allow optimum
adaptation to the physical circumstances.

© Siemens AG 2009
Pump diagnosis for monitoring oscillating
displacement pumps
SITRANS DA400 is a diagnostic device for continuous status
monitoring of oscillating displacement pumps. The device
detects even the tiniest leakages at the valves in oscillating
displacement pumps. No additional troubleshooting is neces-sary.
The principle is based on the measurement of the acoustic
emission caused by the creation of cavitation in the case of
leakages. In addition, there is an option for monitoring addi-tional
variables such as pressure or temperature at the
pumps. On achieving certain limits, these are signaled to
higher level systems by means of digital outputs or via
PROFIBUS PA. Apart from adjusting the device on site, param-eterization
by means of PROFIBUS is also possible.
Large amplitudes, caused by leakage in the intake valve, indicate the defect.
SITRANS DA 400 increases plant availability by means of
• significantly shorter downtimes
• extended maintenance intervals, as pumps only require
maintenance work when their condition demands it.
• avoiding consequential damage due to failure, because de-fective
parts are replaced long before the entire compo-nent
fails. In addition, the early detection of leakages per-mits
optimum forward planning of the maintenance
measures. The operational method of a plant can also be
adapted, thereby improving availability.
The status-oriented maintenance also contributes to energy
saving: A premature drop in performance is detected at an
early stage and can be rectified by replacement or repair of
the affected parts.
SITRANS DA400 thus makes a considerable contribution
toward reducing the total cost of ownership and raising the
productivity.
SITRANS DA400

Maintenance 2sp

More Related Content

What's hot (18)

Similar to Maintenance 2sp (20)

More from Vahid RG-zadeh (7)

Maintenance 2sp